Diverse demand sparks cutting tool development
Cutting tool developments are a key driving force in manufacturing productivity, accuracy, and quality. At Sandvik Coromant (Fairlawn, NJ) one of the main trends influencing cutting tool design is developing cutting tools for small-part manufacturing, particularly the medical industry, which is seeing a phenomenal growth of 10 – 20% annually. According to John Israelsson, vice president, “Another important thrust is tools to meet multitasking requirements. We have had tools to meet these needs, such as our Capto line, but this is being expanded and includes not only the cutting tools, but the toolholding systems. One of the needs is for longer, yet rigid tools that can reach into limited spaces.
“There is also an increased emphasis on the uses of titanium and titanium alloys.
“We will be showing a new line of high-feed milling cutters, as well as tools for parting and grooving, which are designed with a new modular approach.”
Also being introduced will be products for Swiss machines as well as spindle-integrated Coromant Capto solutions.
Kennametal (Latrobe, PA) is accommodating the switch in the auto industry to more aluminum-silicon alloys as well as some magnesium, according to Bernard North, vice president RD&E. “There is also increasing interest in compacted graphite iron [CGI]. This metal is a variant of ductile iron, so tools that work well on ductile iron can, in general, do the job on CGI as well.
“However, absolute tool life is likely to be less when cutting CGI because of its abrasiveness and higher yield strength. Flank wear is particularly important with this metal.
Among the trends:
- The nickel-based alloys are becoming more difficult to machine.
- Whisker ceramics and improved Sialons continue to be used. With Sialons, we have extended the property range and toughness.
- Titanium/aluminum (TiAl) coatings have improved for cutting stainless, regular steels, and cast irons. This is because PVD technology has improved coating adhesion.
“We have tools to cover this range of turning grades such as KC 5010, KC 5025, KC 5510, and KC 5525. There are also new milling grades.
“Both gold and black TiAlN coatings have better adhesion, and for cutting aluminum give better chemical stability, that is, they dissolve more slowly in ferrous materials, and have higher hardness levels. As a result, tool life is longer and cutting speeds are higher. There are many situations in which customers are running TiAlN tools as fast as those with CVD coatings.
“Coatings have made major improvements. About 90% of all Kennametal tools have coatings. For the greatest portion we use PVD. At the same time there has been a surprisingly rapid development of CVD technology, chiefly improvements in adhesion to substrates and between layers. There have also been improvements in coating smoothness and thickness. Turning-tool coatings are now more than 20 µm and milling tools are up to 7µm.
“There is now greater use of substrates with cobalt content less than 6%. They are used in high-volume ferrous machining applications. This reflects the trend in machining to higher speeds, smaller DOC, and fewer interrupted cuts.
“At the same time, there is a clear trend away from HSS to cemented carbide in end mills because new machining centers with higher speeds are stiffer and need more wear resistant tools.
“Milling is an area where we have made big improvements in indexable end mills. We have a new system called Mill 1. It offers better surface finish, while requiring less power and lower cutting forces. The perpendicularity is now close to a true 90º, and it has good ramping capabilities.
“Another innovation is the insert screw is mounted at an angle, instead of the traditional perpendicular mount. This has two advantages. It pulls the insert into the holder more tightly and has more screw threads engaging the holder. As a result cutting speeds can be higher.
“We are also offering a quick-change design for our square-shank tooling and boring bars in 25-mm size. They are a take-off of our KM micro series.”
“The challenges posed by the poor economy during the last few years infused a “do or die” sentiment among US manufacturers,” says Peter Matysiak, president, Emuge Corp. (Northbough, MA) “With relentless pressure for lower cost and quality improvement, many US manufacturers have taken all the measures necessary to become ever leaner. Now, these companies are certainly meaner on their competition while they enjoy the fruits of a lower cost structure in a rapidly expanding economy. At Emuge, we saw these companies step up investments in key equipment, which they tooled up with higher quality and speed of manufacture in mind. At the same time, the reliability factor of the tooling took a heightened position in the purchasing process. In these plants fewer operators ran more machines, leaving them no time to nurse inferior tools though a day’s work. These manufacturers bought more top-end Emuge tools such as full-speed taps, single and multifunction thread mills, high-productivity end mills, all with exotic coatings, most advanced cutting geometries, and coolant-through-the-tool features whenever possible.
“IMTS will see the introduction of Emuge’s expanded Full-Speed Tapping program, where we have added 10 new styles of Full-Speed Taps. These taps allow tapping at record-level speeds on modern CNC equipment. Among many new products, we will feature our Time-S insert milling system, which allows very high metal-removal rates in most materials and our new Threads-All system, which is a multifunction thread milling insert cutter for large threads.”
“In the last two years, there has been a lot of growth in applications of lightweight nonferrous materials as well as hardened steel and other difficult-to-machine ferrous materials,” comments Ed Galen, Product Manager, Citco Diamond & CBN Products (Waynesboro, PA). “As a result, the market has significantly increased for custom-engineered round tools with brazed cutting edges of PCD or PCBN for milling, drilling, and reaming operations. Custom round tools with fixed cutting edges are intended for machining parts with small-diameter holes of approximately 0.25” [13 – mm] diameter where the restricted space is a problem for insert-type cutting tools. They also apply for parts with relatively tight tolerances in the range of 3 – 5 µin. [0.002 µm] because of the possibility of cutting-edge movement with inserted-type cutting tools.
One of the downsides of custom-engineered round tools has been delivery lead times for designing, prototyping, and fabricating the tools that have ranged from 14 to 28 weeks. To help overcome this problem, Citco will introduce at IMTS a new program that cuts deliveries of round tools by half or more by automating the process. The tool design is accomplished by inputting the finished workpiece dimensions into the program along with the number of flutes, the spindle connection style, and the PCD or PCBN segment design. The software renders a finished print with clearances, secondary angles, and flute design, as well as a solid model that can be viewed on-line. Data from the tool-design program can then be used to rapidly produce a scale model of the tool for approval and for writing the NC-CAM program for manufacturing the tool. Using the new software, Citco’s standard delivery for high-precision custom round tools is 10 weeks, and in some cases as little as four weeks.
Chris Olesch of Sumitomo Electric Carbide (Mt. Prospect, IL) notes, “Our industry moves ahead relatively slowly, with cutting tool development usually ahead of machine tool performance. However, currently 70,000 rpm is achievable on the machine and spindle end, but at this time the inserts won’t hold up. Aerospace is where we most often see new alloys being used, then it falls on the cutting tool makers to develop products that will work Recently there have been some advances in diamond tooling.”
At the show, the company will feature:
- Sumichamfer system, which took existing technology and improved upon it. This version requires only three sleeves for the complete size range, and it works with modified standard inserts. Basically it’s a sleeve that fits around a drill so you drill and chamfer in one step.
- The BN 700 tool has the highest CBN content of all Sumitomo grades, and it provides a very hard antichipping edge that is recommended for cast iron and powdered metal. Currently it is being testing it on CGI.
- SMD replaceable carbide-tip drill, which is available in 3X and 5X diam drill bodies.
“The new realities of global manufacturing demand a much closer relationship between customer and manufacturing supplier,” says Bruce Belden, president, Seco-Carboloy (Warren, MI). “Design changes occur more frequently and require rapid response and very quick turnaround. In these circumstances progressive metalworking shops can thrive if they select the most technically advanced and productive tools available, and learn from their tooling supplier how to put them to use profitably. This is one reason why Seco-Carboloy recently implemented a comprehensive training and education initiative. We want to help ensure that North American manufacturers remain globally competitive.
“At IMTS, we will be highlighting our TP Triple-Zero family of insert grades for turning steels and stainless steels. Seco-Carboloy’s TP1000 grade, in particular, was designed for dry machining through a combination of wear resistance and edge toughness. Using TP1000, we’ve been able to demonstrate in numerous applications how getting rid of coolant can extend tool life. Two additional grades round out our new TP Triple-Zero insert line. TP2000 offers reliability and improved surface finishes in medium-duty turning of steels because its toughness resists chipping. TP3000, which combines superior core toughness, high wear resistance and sophisticated chipbreaker geometries, is especially designed to withstand heavy roughing, interrupted cuts, high-feed applications and processes on materials with high piece-to-piece or batch-to-batch variability.
“Seco-Carboloy is also introducing a new line of perfoMAX indexable insert drills that have a combination of features that allow drilling with much faster speeds and feeds even on applications with long overhangs, workpieces with poor fixturing, and thin-walled parts. The entire perfoMAX drilling line, which covers a range of 0.594 – 2.375” [6 – 60-mm] diam and drilling depth capabilities from 2XD to 5XD, uses square inserts with 90º corners. The drill body resists deflection and evacuates chips. Plus, the drills have a non-stick coating that further enhances performance and drill life.
“Also new at IMTS will be a number of milling innovations, including a new Super Turbo mill that is intended for rapidly removing large amounts of metal. The Super Turbo Plunge Mill incorporates a 93º lead angle, which provides a clearance angle of 7º that permits up-copying, or machining in the Z+ direction after plunging down with the cutter to the required depth. This technique further increases productivity and machine utilization.”
Quality workholding systems are essential to part precision. Management executives of Schunk Inc. (Morrisville, NC) note that a major trend in the workholding area is that manufacturers are willing to invest in process improvements that result in increased productivity. It seems that customers will invest a smaller amount in productivity improvement, such as a quick-jaw-change chuck, a quick-change-pallet system or an automatic clamping device, instead of making a larger capital investment like a new machining center.
This type of investment allows them to use their existing machines longer and, at the same time, include the new technologies that help reduce setup times/idle times of their machining, thus reducing setup costs. The trend is also confirmed if you have a look at machine sales over the last two years. Customers tend to use their machines for a longer time, rather than invest in equipment to stay competitive with their production process.
“The tooling area shows a similar trend,” explains company representative Matthias Koch. “Customers want to have tools and machines that can do more than just one operation. This also results in reduced setup times as fewer tool changes are required, thus resulting in a reduction of setup costs. At the same time, high-speed machines result in higher requirements in tooling of these machines. In the same line, balancing tools becomes more critical. Toolholder imbalance can have major effects on the workpiece surface.”
Featured Schunk products include:
- Improved THW Plus chuck, which expands application flexibility by improving productivity and enhancing operational safety. Improvements include larger through holes.
- Easily interchangeable center sleeves that the operator can change quickly without taking the chuck off the machine.
- Hardened chuck body and induction-hardened guideways for high resistance against wear and increased chuck life.
- Strategically placed seals.
- Lower profile direct mounts.
- The new wedge-bar system to enter the chuck body.
“Customers’ needs for application assistance and problem-solving support has grown,” according to De-Sta-Co Industries (Madison Heights, MI ) vice president, Kel Landers.
“This is due to the increased need to reduce manufacturing costs and improve productivity and quality. In addition, our customers no longer have the engineering and support staffs they had several years ago.
“We are focused on designing products that reduce setup time, reduce cycle time, eliminate repetitive motions, and improve safety. This then leads to reductions in cost, lead times, and inventory levels in addition to improvements in productivity, quality, delivery, safety, and ergonomics.
At the show, De-Sta-Co will launch StrongHold Select, a series of hydraulic and pneumatic products that are designed to offer longer product life and higher life cycle. Plus, they are MRO interchangeable. “In addition, we will feature our toggle clamp series [2002/2007/2010] that offers over twice the holding capacity in the same envelope size as previous generation models,” says Landers. “This allows users to substitute a smaller and lighter-weight clamp.
“And, our Robohand DirectConnect technology product line will be on display. Grippers, base slides, thruster slides, rotary actuators, and mounting stanchions can be assembled into pick-and-place modules without adapter plates, reducingh weight, setup time, and cost.”
Other developments in workholding design also feature greater simplicity and rapid setup.
“Parking a fixture on a pallet in a cell or on an extra OEM table has been an accepted practice to eliminate setup time,” notes Gerard Vacio, product manager, workholding systems, BIGKaiser (Elk Grove Village, IL). “However, when these fixtures remain idle for any time, the columns and tables to which they are mounted become very expensive parking places.
“At the same time, JIT practices have manufacturers producing fewer parts per run. As a result, savings can be gained in tooling costs and manufacturing floor space by loading only those fixtures needed for the next production cycle. By switching to a quick-change modular clamping system, such as our Unilock, manufacturers can downsize pallet pool requirements or get by with dual-table machining centers.
“Since dual-table machines and those with pallet pools can be loaded while the machine runs, the costs of extra tombstones and tables can be minimized. Unilock creates a virtual pallet pool by allowing any fixture to be loaded, anytime, on an available machine table or column face.
“A modular quick-change clamping system can change-out a fixture with the same amount of time and effort it takes to change a workpiece. Instead of leaving setups on idle machine tables, fixtures and their associated tooling are retrieved from storage and positioned and clamped using precision-ground clamping knobs.
“Manufacturers who frequently find their evening and weekend workload consisting of more part numbers than they have available pallet locations in their pool may require workpiece changes to achieve nonstop production. If you have someone on site to remove completed workpieces and replace them with the next part in the batch to keep the machines running, then you are able to change a fixture. BIG Kaiser Unilock allows that fixture change to occur quickly and accurately, thus reducing the number of extra machine tables and tombstones required to keep a cell running.”
Cautious optimism seems to be the rule in manufacturing, as indicated by the comment from Spencer Hastert, president, NorthTech Workholding Inc. (Schaumburg, IL) “Even though manufacturing continues to feel domestic and international pressures, some positive trends are beginning to take shape. After a long drought, some are adding capacity. Also, jobs continue to be captured from waning competitors, creating the need for new equipment and tooling.
“Within the workholding world, we have seen increased demand for custom workholding solutions using niche, specialty products. Also, the prolonged downturn in manufacturing has resulted in a ‘procrastinate until it’s a crisis’ mentality. Quick deliveries have become the primary point of discussion, in some cases before price. The winners in this market will be the companies that foresaw and prepared for this recovery as well as those companies that are willing and able to take decisive actions to get ahead of the curve. Management’s confidence and courage will surely be tested.”
At IMTS NorthTech Workholding/Kitagawa will introduce:
- Extra-long-jaw-stroke specialty chucks. The ML-Series power chucks offer specialty workholding features in a standard, off-the-shelf product. They will be available in three basic configurations.
- ML 3-jaw, long-stroke chuck with up to 1″ (25-mm) stroke per jaw as standard. This chuck is designed for workpieces with flanges.
- MDT 2-jaw long stroke chuck useful for square, rectangular or unusually shaped workpieces.
- MDV 1-jaw long stroke chuck allowing single-jaw clamping of workpieces using a nesting locator or fixed jig for location.
All three versions are available in 6 and 8″ (152 – 203-mm) sizes.
Kitagawa DL-Series Power Chucks for rotational workholding, are said to be the first radial guideway power chucks with no jaw lifting and Z-axis repeatability with near-zero tolerance. Traditional workholding solutions for length control involve some sort of “pull-back” chuck. In most cases, jaw stroke length has to be compromised. Also, traditional solutions may interfere with Z-axis loading of the workpiece.
This chuck actuates and clamps the workpiece using traditional radial actuation. Then, in the second part of the actuation, the DL-Series chuck performs a final axial pull-back movement to a fixed stop. A two-step actuation ensures accurate length control and axial repeatability while standard longer jaw stroke lengths are maintained. The DL-Series Power Chuck is available in 6 and 8″ (152 – 203-mm) sizes.
SMW Systems, Inc (Santa Fe Springs, CA) vice president of Operations Steve Brown notes: “The recent downturn has hit all of us hard, but many, including SMW Systems, have benefited from the intense pressure for metal cutting manufacturers to become more productive. Typically, the surviving manufacturers have improved production efficiency by upgrading and implementing new technology during the hard times. One example is the multitasking lathe concept in which small batches of parts are produced in fewer operations. These are expensive machines and every hour of setup downtime costs a lot. As a result, sales of our Ultimate Chuck with quick-jaw-change system have been strong. All three jaws can be changed in a minute and a single set of jaws adjusted over a wide diameter range. And, the accuracy of the system allows second operation soft jaws to repeat within 0.0005” [0.013 mm] TIR without time-consuming re-boring. On multitasking lathes, especially those with two chucks, the cost savings for setup changeover is huge.
“Also for reducing setup downtime, we offer the SetupSwitcher manual pallet changer for small-volume VMC work. The complete table setup can be changed in a minute, and repeat setups stored on extra low-cost pallets can be ready to be on the machine table in perfect alignment in a minute.
Expanded Thinbit tooling line is designed to cut thread sizes 6, 10, 12, 14 and 16 TPI in diameters from 3/16 to 1/2″ (5 – 13 mm). Tools have geometry to cut a specific thread profile or the lathe can be set to cut alternative thread sizes.
Tools can also cut grooves to 0.004″ (0.10 mm). Other products are designed for grooving and face grooving to 1″ (25 mm).
Kaiser Tool Co.
New Tooling Line
Solutions for internal turning, grooving, and threading are provided by the company’s CoroTurn XS line. It features four sizes, CXS-04, -05, -06, and -07, each including inserts for a range of hole diameters and available in different lengths. These inserts fit into boring bars designed with internal cutting-fluid supply directed at the cutting edge via nozzles. Boring bars range from 10 to 25.4-mm diam. Inserts locate precisely into the boring bars. The line is intended for precision small-part machining in sliding headstock CNC machines.
Swiss-Type Lathe Tools
Compact, high-precision tool system for Swiss-type lathes controlled by CNC and for Swiss-type automatics. The Swisscut toolholders provide easy and accurate indexing of the insert. The tangentially clamped insert can be indexed without removing the toolholder from the machine turret. Clamping and releasing the insert can be accomplished from either side of the toolholder. Bottom and rear prisms provide high stability and precision when turning in alternating directions or where relatively high loads are applied. The back clamping option of the Swisscut enables the user to clamp the insert in the holder from the opposite side of the insert. Insert is clamped by a screw which pulls the insert into the pocket by the threaded bushing. An O-ring mounted on the screw prevents the screw from falling out of the pocket while the insert is being replaced.
Ph: 817-258 3200
KUB Duplon drills are designed for small bores, and high cutting speeds and feed rates. A feature of the new drill is the shape of the steel drill body, with a solid carbide head that’s securely joined to the body by a special process. The radial land on the drill head is produced after the connection is made. These drills come in diameter ranges from 8 to 16 mm and are usable to depths of 3 X and 5 X their diameters.
Komet of America Inc.
Constant-Speed Tapping Heads
In constant-speed tapping (CST), the machine spindle runs in one direction at the programmed speed, and tap reversal occurs within the tapping head. Production rate promised by the programmed spindle speed will be achieved, and tap life is increased because rpm fluctuation (common to machine-reversal tapping) is avoided. These CST units come with a variety of shanks, capacities, and tap holding systems, with or without coolant-through capability.
Tools for Dry Machining
Combined with a drill point design intended for chip breaking and a flute design for chip evacuation, diamond-like carbon (DLC) coating enables DLC drills and end mills to do dry and semidry milling of aluminum. Aqua Coating for drills is a patent-pending TiAlN coating that produces a heat and wear-resistant film with lubricating properties, and is said to increase tool life 2 X over conventional drills. Effective drilling is achieved using micrograin carbide substrate with excellent heat, wear, and heat-crack-resistant properties. A patent is pending on the Aqua drill’s special cutting-edge shape.
Nachi America Inc., Cutting Tools Div.
Called the GU/GT 500 DZ line of drills, these tools are offered for a wide range of applications including nonferrous metals, high-tensile steels, stainless, cast iron, and aluminum. The GT 500 DZ combines the manufacturer’s Firex coating with a powder metal steel substrate for machining of high-tensile steel in medium-size batches. The GU/GT DZ series includes models with various screw-machine and jobber lengths, and diams from 1.00 to 14 mm.
The 7791VS series of plunge cutters reportedly can cut cycle times by as much as 90%. They offer high metal removal and good chip evacuation, and principally Z-axis cutting action that reduces power consumption by decreasing cutter forces. Diameters available are 1.5 – 6″. Metric diameters available are 40 – 125 mm. The tools can be used on all steels and cast irons, aluminum and alloys, and high-temperature alloys.
Solid-Carbide End Mills
HSC Feed end mills are designed for roughing and semifinishing of hardened die and mold steels. With chip loads to 0.031″ (0.79 mm) per tooth and cutting speeds exceeding 650 fpm (198 m/min), the tools can run at table feeds of more than 500 ipm (12.7 m/min). High-feed milling of materials such as P20, H13, and S7, with hardness to almost RC 60 is possible, and the mills also perform well in carbon and alloy steels, cast iron, and stainless.
Consisting of a nanocomposite material for hardness and resistance to oxidation, Hitachi’s TH coating permits the high-speed direct milling of hardened steels. Machining efficiency is reportedly double that of tooling that uses conventional coatings. The TH coating is also said to increase tool life, while improving the finish quality of prehardened (RC 35) and hardened steels (RC 45 – 60).
Because the TH coating generates less heat when machining, it’s suitable for dry cutting applications.
Vega Tool Corp.
Solid carbide thread mills are available in decimal-inch, metric, and pipe-thread sizes. Thread mills are also available as blueprint specials per customer specifications. The company will also exhibit its new line of quick-change Cost Cutter hex-drive combination drills and taps, which are intended for on-side drilling/tapping operations.
North American Tool Corp.
EWN heads with Coromant Capto connection are intended for boring operations on mill/turn centers or multitasking machines. The heads give Capto users improved stability and balance during high-speed boring operations with diameters from 1.260 to 8″ (32 – 203 mm). Three different insert holders can be mounted in the opposite direction for changeover to back boring. These heads fit into Capto basic adaptors, extensions and reductions, and fit Coromant Capto spindles and clamping systems of mill-turn centers and lathes.
BIG Kaiser Precision Tooling
Described as the manufacturer’s next generation of mid to large-platform tool-measuring and inspection systems, the Series 2500 TMM presetter can be configured to handle small tools or those to 1000 mm long and 950-mm in diam. A thermally stable mass, compact footprint, and motorized positioning are standard. Options include a high-precision quick-change spindle system, and an upgrade to three-axis automation.
Rotary Tables and Angle Attachments
Kitagawa’s MR-Series rotary tables employ a new triple-disk clamping system, and come in diameters from 6.5 to 12.60″ (165 – 320 mm) with ±10 sec indexing accuracy. MST Rite Angle attachments are interchangeable among machines with the same taper and flange by changing positioning accessories. They accept industrial standard collets and accuracy is guaranteed at 0.0002″ (0.005 mm) at the cavity. Another new item, the MST Lite Duty angle attachment, is primarily intended for drilling and tapping jobs.
Tecnara Tooling Systems
Quick-Change Pallet Clamps
Patented VS clamps locate and clamp pallets to machines quickly and accurately, eliminating inspection and manual bolting. Changes to a part design are accommodated by reworking the fixture and modifying the machine program. With the pallet clamp, the fixture is automatically located (within ± 3 µm) and clamped. Setup time is reduced to seconds. When combined with a pallet changer, the VS pallet clamp increases productivity even when producing the same part. Other features include patented two-surface location and spring locking with hydraulic release.
Kosmek (USA) Ltd.
Grooving and Threading Tools
Expanded line of integral-style toolholders called Groovidex offers four-edge performance to improve productivity. If one edge on an insert fails, the others are unlikely to be affected. Stability of the insert is established by the insert screw, and does not depend on the insert edges. The line is available in a range of insert widths and grades, including a full metric offering.
Manchester Tool Co.
A milling cutter designed for plunging operations with high metal removal rates, the Super Turbo Plunge Mill incorporates a 93º lead angle, which provides a clearance angle of 7º that permits up-copying or machining in the Z+ direction after plunging down with the cutter to the required depth. The cutter uses 12-mm high-positive inserts. The line is available as shank end mills and arbor/shell mill bodies as well as replaceable-head styles. It includes eight cutters ranging from 1.00 to 2.50″ (25.4 – 63.5-mm) diam.
The 500-fold incident-light camera of the genius 3 micro inspection machine can measure tools with a diam as small as 0.1-mm. Tool parameters like clearance angle, rake angle, and core diameter can be measured by evaluating a measuring area of 0.1 X 0.1 mm on the tool surface. It’s equipped with five CNC-controlled axes, power-operated tool-clamping chuck, and software to provide automatic and user-independent measuring results.
The 4 and 5-mm COFA cutting tools employ a patented design with a unique cutting blade for deburring elliptical holes and irregular parts as well as round holes and flat parts. It creates a true radial break edge on through-holes, allowing 100% burr removal. The standard carbide blade is TiN-coated. The tool can reach down to hole diameters as small as 0.158″ (4 mm) and larger than 4″ (102 mm) to create a smoothly tapered edge break from 0.005 – 0.020″ (0.13 – 51 mm) based upon tool size.
Heule Tool Corp.
Ph: 513-860-9991 ext. 17
Sino-T toolholders are designed with a stiff body as a clamping medium providing consistent support across the entire clamping zone. Holder is easily activated to achieve stable clamping for high-cutting torque transmission. Unit has excellent damping characteristics to improve tool life and surface quality. Clamping diameter can be reduced to accommodate almost any holder by using intermediate sleeves.
FlipCut tools perform back spotfacing and chamfering operations in one setup. Cutter flips open to machine then flips back to the closed position for withdrawal. Also shown will be braze diamond reaming and boring tools, burnishing tools, hole deburring tools, and contouring systems.
Ph: 803-438-4000 ext. 218
This high density long (HDL) vise has two 4″ (100-mm) capacity stations with hard jaws that provide repeatable clamping to 0.001″ (0.03 mm). The manual model provides up to 6316 lb (28 kN) clamping force at 70 lb (32 kg) torque, and the hydraulic model delivers 7800 lb (35 kN) force at 5000 psi (35 MPa). Features include: hard jaws or quick-change machinable jaws in 7075-T6 aluminum or 65-45-12 cast iron; manual and hydraulic models for use on VMCs and HMCs; self-adjusting holding block for setting jaws quickly; and adjustable preload.
Kurt Manufacturing Co.
Custom Round Tools
Software enables design and fabrication of PCD and PCBN-tipped custom round tools for milling, drilling, and reaming. Finish workpiece dimensions are input to the program along with the number of flutes, spindle connection style, and the PCD or CBN segment design. The software delivers a finished print with clearances, secondary angles, and flute design. Data from the program can be used to make a scale model for approval. After order confirmation, the design is manufactured. Standard delivery is 10 weeks.
Citco Diamond & CBN Products
The StrongHold Select series of hydraulic and pneumatic products includes hydraulic swing clamps, work supports, threaded body cylinders, square body cylinders, pneumatic swing clamps, and accessories. They work together as part of a workholding system, allowing users to secure all the clamps from one power source. Operators can clamp an entire fixture from one location.
First product of the company’s G6 coating generation, Balinit Alcrona–an aluminum-chromium-nitride (AlCrN) coating–is claimed to offer unmatched hot hardness and oxidation resistance. In conventional machining operations and in applications involving heavy mechanical and thermal stresses, these properties are said to translate into outstanding wear resistance. The manufacturer describes the coating as opening up a new productivity dimension in milling and hobbing operations. Balinit is reportedly well-suited for dry and wet machining of unalloyed steels as well as high-strength, high-hardness steels (to RC54).
DigiBore heads feature sealed electronics. Self-balancing, precision boring heads incorporate electronic transversal measuring technology for 0.0001″ (0.003-mm) accuracy. The zero-out function displays ± fine adjustments in 0.0001″ increments. The heads offer a 0.118 – 8.195″ (3 – 208-mm) boring range with coolant through the tool to 580 psi (4 MPa) at a maximum speed of 16,000 rpm.
Quick-Change Tooling System
Mach-1 quick-change tooling system is intended for installation on new or existing Bridgeport or other brand knee or bed mills. It includes a patented mechanical drawbar with a 600-lb (2700 N) die spring that replaces the machine’s existing drawbar. To change tools, you insert a toolholder or collet into the spindle, push the quill handle back, and release the handle. A ground pull stud snaps the collet/toolholder in place. Patented collet closer secures the tool in the collet to maintain its Z position. Optional drive collar uses the spindle nose to drive the tool, making the holder more rigid.
Hardinge Inc. Workholding Div.
Line of Demmeler modular fixturing for welding has expanded its product range by adding more than 20 new fixturing components and a new table size. Exhibit will include a range of modular fixturing for welding and other modular fixturing solutions for machining and inspection.
Alpha 4 Plus Micro is the company’s smallest solid-carbide drill with internal coolant in 8 X D and 12 X D version. Alpha Point is a tool system with the TCT tip that can be replaced, even with the holder clamped in place, and internal coolant. Alpha 4 TFT 8 X D and 12 X D are solid-carbide deep-hole drills with internal coolant for drilling deep holes.
Modular Boring System
The URMA IntraMax system enables users to assemble the right boring tool for any application by using an interlocking combination of adapters, extensions, and boring heads. By varying the size of diameter extenders, the same roughing and fine-boring heads can be used for inside boring diameters from 1.9 to 14″ (48 – 356 mm) on a 40 or 50-taper spindle. The system can also turn ODs from 0.35 to 9.8″ (8.9 – 250 mm). Single-pass roughing/finishing operation is achieved by offsetting the roughing head from the finishing diam, then lowering the finishing insert to allow the rougher to lead.
Command Tooling Systems
Smooth-Cutting Shoulder Mill
The Xtra·tec F4042 universal shoulder milling cutter uses high-positive rhombic inserts to provide very good cutting performance at low power consumption. The tools’ extremely smooth cutting action is said to be practically free from vibration, resulting in excellent workpiece surface finish, long tool life, and improved productivity. The cutters mill a true 90º angle, keeping the shoulder face free of steps, and are especially recommended for roughing and finishing steels, cast irons, and stainless materials. Tool bodies are manufactured with a hard, nickelized protective layer to lower friction in chip flutes, and decrease corrosion. Three types of inserts representing cutting lengths of 8, 12, and 16 mm are available for cutters with diameters from 10 to 160 mm.
Made from micrograin carbide, the PHP 3 Flute Drill series enables high-speed machining of aluminum and other nonferrous metals without internal coolant supply. With the right coating, it can be used on cast iron and other short-chipping materials. A standard length drill with a 130º self-centering low-torque point and 30º helix with rolled-heel flute construction, it’s manufactured to a DIN 6537L flute and overall length. It can drill holes to 5 X D, and comes in sizes from 1/8 to 5/8″ by 32nds, and metric sizes from 5.00 to 16.00 by 0.500.
Precision Twist Drill
Miracle W Star coolant-through drills are said to drill to depths of 8 X diameter 20% faster than standard tools by eliminating pecking cycles. Cutting edge and flute design features provide excellent chip control and chip evacuation, allowing use of the drills on general machining ceners without high-pressure coolant capability. Drills are produced from grade VP15TF coated carbide, which resists built-up edge and provides ood fatigue resistance at extreme drilling depths. The tools are available in diameters from 0.0125 to 0.500″ (0.32 – 12.7 mm).
Designed for the mold-making industry, DM milling tools can be applied in most applications that require shallow milled features. Inserts are available for chamfering, centering and chamfering, slot milling, end milling, and full-radius rough and semifinish pattern milling. Standard carbide shanks for shrink-fit holders and steel shanks for collet holders are available. Patented insert-locking mechanism allows insert change with less than 90º of rotation.
Horn USA Inc.
Superoll burnishing tools use plastic deformation to cold work a metal surface. Finish may be 2 µin. or less. Typical applications are burnishing connecting-rod bearing surfaces, cylinders, piston housings, valves, and valve seats. Tool can debur workpieces with 0.176 – 7.917″ (4.5 – 201-mm) IDs and 0.97 – 2.477 (25 – 63-mm) ODs.
WTiQ-323 can chuck 15 – 25″ (381 – 635 mm) wheels at up to 2800 rpm. Advantages include: Changeover in less than 5 min; several centering options; and through-chuck air and coolant to facilitate vibration dampening, air clamp confirmation, and coolant flush. Wheel chucks are available with a variety of tooling options, many of them specific to individual wheels.
Logansport Matsumoto Co.
Featured will be inserts for turning high-temperature alloys, coated inserts for turning gray cast and ductile iron, as well as octagonal insert face mills, and carbide-tipped drills. Grades KC5510 and KC5525 can machine at speeds of 300 – 400 sfm (91 – 122 m/min). Also shown will be grades KC9315 and KC9325, which are coated carbides designed for turning gray cast and ductile irons. Advanced coating technology is used on the new steel turning grades, KC9110 and KC9125.
Products to be shown include Valturn turning system, Valturn Progrip toolholders, Valgroove parting and grooving tools, and Valmill milling products. Also available will be Modco engineered tooling, HSK tooling, VM modular quick-change system, Shrinker tools, and Valenite gaging tools.
New series of TiN-coated step drills have three flats ground on the shank to prevent the drill from slipping in the drill chuck. The TiN surface treatment reduces friction and extends tool life to much as six times over uncoated step drills. A balanced double flute provides two cutting edges for faster cutting in soft or hard material. TiN-coated step drills come with 1/4 and 3/8″ (6.4 and 9.5-mm) shanks.
M.K. Morse Co.
Countersinks and Counterbores
Three-flute countersinks, from 1/2 to 1 1/4″ (12.7-31.75-mm) diam, are available in 60, 82, and 90° included angles. They have a combined round and hex shank design that facilitates toolholding in collets, three-jaw drill chucks, and cordless drills. Extended-length shank countersinks in 82 and 90° angles, with shank lengths of 4 and 6″ (102 and 152 mm) are also featured. Inch-standard counterbores incorporate a one-piece tool design with integral pilot. The program covers a full range of diams for socket-head capscrew assembly requirements.
Robert Charles Cutting Tools
Grades for Nodular Iron
CVD-coated grades CA4120 and CA4115 were developed for both continuous and interrupted cutting of nodular cast iron. The coating has a fine columnar structure said to increase resistance to cracking, wear, and chipping. Claimed tool life is double that of conventional tools. CA4120 has very good chip resistance, making it suitable for interrupted cuts; CA4115 offers superior wear-resistance for continuous cutting operations. The grades are available in five chipbreaker geometries to cover a variety of cutting applications.
New series of form toolholders designated Stah uses throwaway-style inserts. These holders can accommodate part forms to 1 1/4″ (32.5-mm) wide and a 7/16″ (11-mm) depth of cut–7/8″ (22 mm) on diameter, and can be used on Acme, Davenport, New Britain, and CNC machines. The holder for Davenport machines has a 9/32″ (7-mm) depth of cut–9/16″ (14 mm) on diam. Holders use throwaway inserts with a simple backup anvil; there’s no need for custom-made screwed-on anvils.
Somma Tool Co.
End Mills and Drills
Company will feature an expanded line of high-performance carbide end mills and drills as well as cobalt HSS end mills and countersinks. Tools include carbide end mills engineered for mold and die making, as well as another line for high-speed aluminum milling. Also available are variable-helix carbide end mills for increased speeds and smoother finishes in stainless, high-temperature alloys, and titanium alloys, as well as a line of carbide drills for holemaking in materials with hardness >RC 40.
Melin Tool Co.
Tough End Mills
New Z-Carb-HTA carbide end mills feature patented geometry enhancements that reduce chatter, increase tool life, and speed machining of heat-resistant alloys. Tests versus standard-geometry mills have shown the design can increase axial depth of cut nearly three times without chatter and double radial width of cut. The tools also use the company’s Ti-NaMite-A coating to resist heat generated in aggressive cutting operations and further improve tool life.
SGS Tool Co.
A six-jaw pressure-equalizing “ball chuck” allows high-low pressure-differential chucking or the ability to effectively grip thin-wall parts in a single chucking, minimizing secondary machining operations. The chuck uniformly distributes a 3.6:1 power ratio to the workpiece through six internal, connected jaw force distributors, resulting in twelve equally spaced contact points on the workpiece. Each contact point contains a standard or custom carbide insert, and distributes an equalized portion of the total gripping force. Also on display will be universal power chucks in three designs, as well as a counter-centrifugal chuck said to gain jaw force at speeds to 2500 rpm, allowing lower initial drawbar pressure and reduced jaw force loss at higher speeds.
Hydraulic Corner Notcher
Model 206/V features variable angle cuts from 30 to140º, 0.25″ (13-mm) capacity, and automatic blade adjustment. Unit also has an oversized hydraulic reservoir for continuous production.
Heck Industries Inc.
Accu-Length CNC collet chucks are fixed within the core chuck bore and a tapered sleeve pushed forward over the collet, resulting in precise Z-axis workpiece positioning. Runout is 0.0003″ (0.008- mm) TIR and they are available in a wide variety of collet styles.
Steadyrest and Gripper
Auto Rest has a sliding wedge design which features increased clamping range, integrated roller, pin and chip deflector, and quick-change cylinder. Centerline control has been incorporated on all arm-retracting grinding Auto Rest models, this allows precise centering and size adjustment without repositioning the entire unit.
Arobotech Systems Inc.
Muiti-Vise system provides clamping pressure up to 3000 lb (13,200 N). Jaws are dowel pinned for repeatability and easy replacement. Multiple parts can be held with a single unit. Advantages claimed include decreased load/unload time, increased spindle time, and decreased need for operator attention.
This article was first published in the August 2004 edition of Manufacturing Engineeringmagazine.